Butt Fusion and Electrofusion Equipment and Tooling

Butt Fusion & ElectrofusionEquipment & Tooling

Manufacturing Excellence from the Fusion Group

THE COMPANY

Founded in 1971, Fusion Group is a multinational company with its headquarters and principal manufacturing site located in Chesterfield, England.

Fusion Groups Equipment Division is a world leader in the manufacture of automatic and manual butt fusion machines, electrofusion boxes and tooling for polyethylene pipe jointing.

In the UK, Fusion Group markets its manufactured products through its distribution arm, Fusion Provida. In addition to its National Sales Office in Chesterfield, Fusion Provida has a strategically located hire and service depot network. Contact details for both UK equipment sales and hire are listed on page 55.

Over 60% of Fusion Groups UK manufactured output is sold into international markets through a global network of wholly-owned subsidiaries, joint-venture companies, and agents. Contact details for Fusions international sales team are provided on page 54.

The Fusion Group is an entrepreneurial award-winning innovator. A brief overview of Group activities is provided on page 53.

Fusion GroupChesterfield Site

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Every effort has been made to make the information in this brochure as up-to-date as possible. Fusion Group operates a policy of continuous product improvement and, therefore, reserves the right to modify product specifications in line with market requirements. If you have any questions regarding the products in this brochure please contact the Fusion Equipment Hotline: +44 (0)146 68666

3 Web: www.fusiongroup.com Email: [email protected]

SCRAPERS

30-31

CLAMPS

3-37

TEST CAPS/CUTTER KEYS

38

STRAP CLAMPSPOWERCLAMP

ELECTROFUSION CONTROL BOXES

4-9

39-4

CONTENTSELECTROFUSIONBUTT FUSION

BUTT FUSION LINERS

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DEBEADERS

16-17

PIPE SUPPORT ROLLERS

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BUTT FUSION MACHINES

4-14

POST SQUEEZE OFF CLAMPSREROUNDING TOOLS

43

ANCILLARY EQUIPMENT

DRILLING EQUIPMENT

47-48

PIPE CUTTERS

49-50

SQUEEZE TOOLS

44-46

GENERATORS

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JOINT RECORDS

DATA RETRIEVALJOINT ANALYSIS

ASSET INTEGRITY

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jointmanager

4BUTT FUSION - WHAT DO I NEED?

A basic butt fusion kit for jointing polyethylene pipes should include:-

Butt fusion machine Generator Pipe cutter Pipe support rollers Welding tent/shelter and ground sheet

Depending on your specific requirements, you may also need:

External/internal debeading toolsData transfer optionsPipe end coversIndelible marker pen for marking beads

New to butt fusion? Fusion Group can provide training on all of our products tailored to your specific needs. Contact the Equipment Office on +44 (0) 146 68666 for more details.

We have also produced a Good Guide to Butt Fusion which takes you through the process step-by-step. You can download a copy free of charge from our website at www.fusiongroup.com

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Good Guide to Butt Fusion and Electrofusion Jointing

ItemMachine Size Range (mm)

Page(s)63-180mm 63-50mm 90-315mm 160-400mm 315-500mm 400-630mm

Automatic Butt Fusion - Gator (Hire Only)

Pages 8-10

Pipeliner Pages 11 & 1Welda Page 13Welda Station Page 14

PRODUCT DETAILS


Globally recognised as the market leader in pipe jointing equipment with the most efficient, robust and easy to use machines providing 100% successful joints time after time.

In the utility industry where quality and safety are paramount, Fusions butt fusion machines lead the way. Fusion has created the Gator range of machines capable of jointing pipes from 63mm to 630mm.

Fusions Gator range offers full automation of all functions that contribute to a successful joint, including:

Drag measurementTrimming incorporating Fusions unique feathering functionPressure control during the heating, jointing and cooling stagesTemperature control throughout the entire processData captureLinear transducers control the pipe movement and

control the trimming processdistinguish between static and dynamic friction for drag measurementdetects pipe slippagekeeps dwell time (open-close) to a minimumoptimise pipe pressure during fusioncontrol bead sizedetect early pipe removal

On the 500 and 630 machines heater and trimmer loading is fully automatic eliminating manual lifting.

A large selection of languages for screen prompts and data displays are available. Please contact us for further details.

The combination of industry accepted jointing parameters, continuous machine monitored feedback and relevant operator input has produced a system capable of controlling the complete jointing process at all times.

Automatic machine features:

Automatic joint cycleDatabase memory up to 500 joint historyShort dwell time - heater removed in under secondsFast trimming actionOperator friendly machineFast Weld compatibleFailsafe systemOptional barcode reader for ISO standard traceability (Gator 50, 315 and 400 only)

63-400mm 315-500mm 400-630mm

AUTOMATIC BUTT FUSION

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Fusion automatic butt fusion machines - 100% successful joints every time!

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6THE GOOD GUIDE TO: AUTOMATIC BUTT FUSION

Dos and DontsPRE JOINTING CHECKS

Use equipment that is clean, in good condition, regularly maintained and within required calibration/service.

Ensure the correct jointing parameters for the machine and pipe are known and understood and correct parameters are selected.

Ensure the generator is in good condition and has plenty of fuel.

Check that the heater plate is clean - wash only when cold with clean water and dry with a lint free cloth or paper towel. Clean trimmer discs before use with lint free cloth.

Check that the trimmer is clean and that the blades are not damaged and in the correct position for the required pipe size.

Ensure clamp liners and securing screws are of the correct size.

ABF DOS

Always input correct operator code and job code to allow for full traceability.

Always weld in a shelter and on a suitable board or ground sheet.

Check size, SDR and pipe material to ensure compatibility.

Always ensure pipes are aligned correctly and supported on pipe support rollers to minimise drag.

Cover pipe ends to eliminate wind chill to the heater and joint interface.

Clean pipe surfaces inside and out (approx 300mm), clean pipe ends and clamps before inserting pipe into machine.

Position pipes in clamps with the pipe marking to the top and aligned.

Wash the heater plate when cold before every welding session and perform dummy welds when hot to remove fine particles and prevent the production of fumes. Carry out one dummy weld on pipe size 180mm or below, or two dummy welds on larger pipe sizes. The first print out should read Error 0 Abort During Fusion if butted or Error 19 Abort During Soak if prior to butting or Error 3 Abort During Dwell.

Always perform dummy welds after changing pipe size and also if the heater plate has been allowed to cool.

Ensure that when trimming a continuous ribbon of material of pipe wall thickness is produced from both pipe ends before commencing feathering operation.

Always use trimmer/hotplate stands provided.

Always remove swarf from underneath pipe ends and chassis.

Visually check that both ends are completely trimmed.

Always check pipes for alignment and gaps around the entire circumference of the abutted pipes.

Always remove external bead from completed joint, bag and label with corresponding joint number for submission and inspection by the supervisor.

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Dos and DontsTHE GOOD GUIDE TO: AUTOMATIC BUTT FUSION

Dos and DontsABF DONTS

Attempt to use equipment unless trained to do so.

Attempt to weld pipes of incompatible materials or SDR.

Leave swarf inside pipe or on chassis.

Introduce dirt onto trimmed pipe ends whilst removing swarf.

Touch trimmed pipe ends or fitting ends.

Remove pipes from machine before cooling time had elapsed.

Attempt to cut corners in any part of the welding cycle.

Attempt to install pipe until fully cooled.

HEALTH AND SAFETY

Although we make every effort in the design of our equipment to ensure operator safety, it is worth bearing in mind the following precautions:

Do not touch heater plate (unless to clean when cold).

Never allow molten or semi-molten polyethylene to come into contact with skin. In the event of such an occurrence it is recommended that cold water should be used to flush the affected area and medical advise be sought.

DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO PULL THE MATERIAL FROM THE SKIN AS THIS WILL INVARIABLY REMOVE THE SKIN AS WELL.

Avoid contact with trimmer blades when cleaning and especially when in motion, blades are very sharp and could cause serious injury.

Do not attempt to operate the trimmer whilst it is out of the machine or attempt to by-pass the safety switch.

Keep fingers and hands away from the pipe end, chassis, trimmer and heater while in operation.

Do not attempt to lift or move lengths of heavy pipe without assistance. The requirements of manual handling should be adhered to.

An audible alarm is fitted to automatic butt fusion machines to warn of impending movement.

Normal precautions should be observed when handling electrical equipment and, for safety reasons, all 110v portable generator sets should be centre tapped for site use +55/0/-55 volts.

Health and safety regulations insist upon the wearing of personal protective equipment such as gloves, safety glasses and safety boots.

ALWAYS REMEMBER THAT ALL JOINT RECORDS ARE AUTOMATICALLY STORED AND SHOULD BE DOWNLOADED ON A REGULAR BASIS TO ALLOW FULL TRACEABILITY AND TO PROVE THE INTEGRITY OF WORKMANSHIP

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8GATOR 180, 250, 315 & 400 (BUTT FUSION - AUTOMATIC 63 - 400mm)

SPECIAL FEATURES

Unique fast clamping system allows rapid and easy pipe loading as well as removing the need for additional toolingCurved trimmer blade ensures optimum cutting performanceLight and compact heater and trimmer standFast twist-lock system for rapid installation of trimmer and heater (50 & 315 only)Automatic interlock for correct heater temperatureReplaceable heater surface platesHard anodised trimmer discsDetachable stainless steel cradle for on site protectionIdeal for in trench work Data transferGator 50, 315 & 400 - National Grid approved

OPTIONAL EXTRAS

LinersBevel liners (for short spigot fittings)PrinterBarcode scannerStub flange adaptorKnife-edge clampTouch key

Machine Type Range (mm) Weight (kg) Fittings Data Retrieval Voltage Product Code

GATOR 180 63mm-180mm 105 YES YES 110V0V

G180110AFE*G1800AFE


G50110AFEG500AFE


G315110AFEG3150AFE


G400MK110FEG400MK0FE

POWER SPECIFICATIONMachine Type Heater Trimmer Controller

GATOR 180 1500W 650W 1100W

GATOR 50 1800W 650W 1100W

GATOR 315 3300W 650W 1100W

GATOR 400 4000W 1050W 1100W

For details of Fusions range of generators see page 51

Check out the award-winning Gator Pipeliner 315 and 400 on page 11

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All machines supplied without liners. Please specify liners when ordering if required* E denotes plug type E = 3 Pin Blue G = 2 Pin Black

MACHINE SPECIFICATION

GATOR 250

GATOR 315


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GATOR 500 (BUTT FUSION - AUTOMATIC 315 - 500mm)

SPECIAL FEATURES

Hydraulic actuation of the trimmer and heaterLinear transducer to control processesFast heater removal (.8 seconds dwell time)Automatic interlock for correct heater temperatureArticulated carriage to aid positioningAdjustable leg supports for easy levellingIntegral hydraulic pipe support rollersUtilises familiar operator friendly Gator computer with additional functionsFull safety interlocks including audible and visual alarms during machine cycles/movementFailsafe error code systemFastweld compatibleData retrieval and processingCurved blade ensures optimum trimming performanceFully automatic jointing cycleDatabase memory up to 500 joint historyOptional barcode reader for ISO standard traceabilityOptional printer unit for joint record printoutFast trimming actionOperator friendly machineFully floating heaterNational Grid approved

OPTIONAL EXTRAS

LinersPrinterBarcode scanner


All machines supplied without liners. Please specify liners when ordering if required

POWER SPECIFICATION


Item Power Requirements

Heater 7500W

Trimmer 1050W

Controller 100W

Minimum Recommended Generator

1kVA 3PH 415V

Item G500

Diameter Range 315-500mm

Gross Weight 750kg

Data Retrieval YES

Fast Heater Removal .8 seconds

Environmental Protection IP54

Dimensions L x H x W (parked) 160x00x1300mm

Product Code G500EAJSXPX

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630

BF 630(BUTT FUSION - AUTOMATIC 400 - 630mm)

SPECIAL FEATURES

Integral hydraulic pipe support rollersHydraulic clamping and trimmer/heater loadingIndependent chassis, power pack and hand-held controller for optimal manoeuvrabilityAutomatic hydraulic trim cycle and featheringPipe slippage is monitored automatically and the operator is prompted to visually inspect pipe alignment by means of the check cycleSoftware and fascia available in a variety of languagesAutomatic interlock for correct heater temperatureRepeatable dwell time of less than 4 seconds helps produce quality points and opens the door for faster welding with revised jointing parameters. A heated pipe end typically loses 3 - 5C per second in normal ambient conditions. All the more reason to make the joint quickly!Security immobiliser restricts access to authorised operators onlyJoint records are stored and can be downloaded via data transfer onto a PC for network analysisComplete in-built diagnostic systemOptional floating heaterNational Grid approved


Item BF630ADiameter Range 400-630mm

Gross Weight 1775kg

Data Retrieval YES

Fast Heater Removal < 4 seconds

Environmental Protection IP54

Dimensions L x H x W (parked) 1700x1365x1700mm

All machines supplied without liners.Please specify liners when ordering if required

POWER SPECIFICATION

Item Power RequirementsHeater 13.5KW

Trimmer Hydraulic

Controller 4000W

Minimum Recommended Generator

0kVA 3PH 415V


The only fully automatic 630mm butt fusion machine in the World!

Available for hire o

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Web: www.fusiongroup.com Email: [email protected]

GATOR PIPELINER 315 & 400(BUTT FUSION - AUTOMATIC 90 - 400mm)

Introducing the new Gator Pipeliner fully automatic butt fusion machine. Based on the Gator 315 the Pipeliner has a gas sprung pivoting heater and trimmer to remove all lifting from the jointing process.

SPECIAL FEATURES

One person machine setupHeater ejects automaticallyAutomatic interlock for correct heater temperatureChassis can split into two manageable modulesOnce in-situ can be operated by one personIncreases productivityFaster joint cycleUpgrade available for existing Gator 315 (refurbishment of heater and trimmer can be included in the upgrade)National Grid approved

OPTIONAL EXTRAS

LinersPrinterBarcode scannerStub flange adaptorKnife-edge clamp

The Pipeliner was the winner of the SBWWI Innovation Award

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POWER SPECIFICATION

Item Power Requirements

Gator 315 Pipeliner

Gator 400Pipeliner

Heater 3300W 4000W

Trimmer 650W 1050W

Controller 1100W 1100W


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Item Gator 315 Pipeliner Gator 400 Pipeliner

Product Code G315110NLE G400110NLE

G3150NLE G4000NLE

Input Supply 110V Units 97-135Vac 97-135Vac

0V Units 195-60Vac 195-60Vac

Diameter Range 90 - 315mm 160-400mm

Gross Weight 175.5kg 9kg

SDR Range (Typical) 7.5, 7.4, 9, 11, 13, 17, 17.6, 6, 3 plus capability for special SDR

7.5, 7.4, 9, 11, 13, 17, 17.6, 6, 3 plus capability for special SDR

Operating Temperature (Range) -10 to +40 C -10 to +40 C

Storage Temperature (Range) -15 to +45 C -15 to +45 C

Data Retrieval YES YES

Environmental Protection IP54 IP54

Unit Weights Insert Module 69kg50kg

Chassis 64.5kg

Controller 4kg 4kg

Dimensions (mm)(L x W x H)

Overall Machine (Parked) 1160 x 80 x 660mm

including protective

carriage

150 x 880 x 780mm

Overall Machine (Unparked) 1160 x 80 x 1170mm 1530 x 880 x 1450mm

Chassis Only 760 x 80 x 470mm N/A

Insert Module Only (Parked) 1100 x 80 x 580mm N/A

Controller 470 x 515 x 500mm 470 x 515 x 500mm

Input Cable (Length) 5m 5m

Hydraulic Hoses (Length) 5m 5m

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GATOR PIPELINER 315 & 400(BUTT FUSION - AUTOMATIC 90 - 400mm)

Pipeliner 315

Quickly separates for person carry Very Compact

Complete Pipeliner 315in parked position

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WELDA 180, 250, 315 & 400 Mk2(BUTT FUSION - MANUAL 63 - 400mm)

FEATURES

Twin dual pipe clampsFast clamping for pipe installation Two centre axial mounted hydraulic cylindersLightweightLarge, easy-to-read pressure gaugeIndependent pressure control valvePressure relief valveMaintains pressure during the cooling process150 bar operating systemUnique curved blade technology for fast and efficient pipe trimming actionTrimmer safety micro switch fitted for safe operationElectronically regulated heater and temperature adjustmentJoins pipe to pipe and pipe to fittings

Product Code Machine Type Range (mm) Fittings Voltage Weight (kg)

W1800MFE WELDA 180 63-180mm YES 0V 95

W500MFE-MK WELDA 50 63-50mm YES 0V 100



Machine Type Heater Trimmer Pump Unit

WELDA 180 1500W 650W 1100W

WELDA 50 1800W 650W 1100W

WELDA 315 3300W 650W 1100W

WELDA 400 4000W 1050W 1100W


Note: The Welda range was developed for international markets and operates on 0V supply as standard. 110V machines are available to UK operators on special request

POWER SPECIFICATION

Welda Mk machines are part of the manual range of butt fusion machines launched by Fusion. They are suitable for welding polyethylene pipes for gas and water pipeline projects and also polypropylene pipes used in industrial applications.

The Welda Mk machines have been designed to meet ISO 1176-1.


All machines supplied without liners. Please specify liners when ordering if required* E denotes plug type E = 3 Pin Blue G = 2 Pin Black

OPTIONAL EXTRAS

LinersStub flange adaptorBevel liners for short spigot fitting

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WELDA STATION315 BUTT FUSION MACHINE(BUTT FUSION - MANUAL 90-315mm)

The Welda Station 315 is a brand new design in manual butt fusion which is manufactured by Fusion Provida in the UK for the international market.

The Welda Station 315 is fixed at a 45 degree angle for ease of loading and underclamping pipes. It is highly manoeuvrable and compact and has the hydraulic control unit mounted on the wheeled trolley. One of the advantages of the Welda Station 315 is that the chassis can be removed for trench work.

Item Description Weight

Welda Station 315 1180(L) x 800(D) x 930(H) mm 9kg

Hydraulic Unit and Trolley

150 bar, 1.1kW, 0V, 50Hz, single phase

109kg

Butt Fusion Chassis 690(L) x 610(D) x 460(H) mm 65kg

Trimmer 650W, 0V 31kg

Heater Plate 3.3kW, 0V 15kg

Heater Stand Removable heater stand 9kg

Minimum recommended portable generator output for field use is: 5kw, 240v single phase


FEATURES

Robust, reliable and low maintenanceQuick removal of chassis, trimmer and heater from trolley for in trench workEasy single person operationEasily manoeuvrable with pull out handlePipe range 90 - 315mm Fast clamping systemPowerpack mounted on trolley for ease of use with ergonomic controlsReplaceable heater surface plates

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BUTT FUSION - LINERS

Butt Fusion liners are designed to maximise the size range of the machine. Liners are available either in a tough engineering plastic or cast aluminium.

Size Product Code Material Machine Diameter *

500X450 BFL500450X50 Aluminium 500




400X355 BFL400355 Aluminium 400



315X280 BFL31580 Aluminium 400, 315

315X250 BFL31550 Aluminium 400, 315

315X200 BFL31500 Aluminium 400, 315

250X225 BFL505 Aluminium 400, 315, 50

250X200 BFL5000 Aluminium 400, 315, 50

250X180 BFL50180 Aluminium 400, 315, 50

250X160 BFL50160 Aluminium 400, 315, 50

180X160 BFL180160PT Engineering Plastic 400, 315, 50

180X160 BFL180160 Aluminium 400, 315, 50

180X140 BFL180140PT Engineering Plastic 315, 50

180X140 BFL180140 Aluminium 315, 50

180X125 BFL18015PT Engineering Plastic 315,50

180X125 BFL18015 Aluminium 315, 50


180X110 BFL180110 Aluminium 315, 50


180X90 BFL18090 Aluminium 315, 50

180X75 BFL18075PT Engineering Plastic 50


180X63 BFL18063PT Engineering Plastic 50


* Liners are designed to fit both Gator and Welda machines

Where 180mm engineering plastic liners are ordered as spares for existing machines the purchaser should check to ensure that the 50 x 180 aluminium liner (into which the 180 liner is to fit) has got a recess machined into it (see picture).

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INTERNAL DEBEADERSA simple and effective tool for removing internal beadsA manual kit for the simple and effective removal of internal beads formed during the butt fusion process for polyethylene pipes in the size range 110-450mm

FEATURES

Rods can be assembled to debead pipe up to 13m in length - more on requestPortable kitBead retained in head after withdrawal Robust build qualitySimple to assemble, easy to useNational Grid approved

Fusions internal debeader allows:

Quality control procedures from visual bead inspection (i.e. bend back test)Quality assurance records (i.e. archiving beads and data print-out for joint history)Removal of internal bead increases flowProtection for pipelines carrying sewage or other media where entrained solids could become attached to an internal bead and cause a blockage

Complete internal debeading kit (product code: IBRTKIT) comprises:

Product Code Description

11769 1 x storage box

11560 1 x drive handle

1459 1 x no. 1 size head

1457 1 x no. size head



n/a Allen keys

n/a 1 x set operating instructions

3740 3 x size 1 rod supports

31754 3 x size rod supports



1859 3 x size 4b rod supports

69046 1 x rod bag

1560 6 x meter rods

1618 1 x 1 meter rod

Extras

9145 Adaptor for 450mm SDR11

91474 Adaptor for 450mm SDR17.6

51416 x screws

ProductCode

Description Weight

IBRTKIT Kit supplied with heads 1,, 3, 4 70kg

IBRT1 Kit with head 1 only 40kg

IBRT Kit with head only 40kg



31681 Spare blade for head 1 and N/A

3187 Spare blade for head 3 and 4 N/A

Note: Each debeader head size has multiple settings. These are referred to in the table as A, B, C or D. To select the correct head size you will need to know the outer diameter of the pipe you wish to debead (see first column) and its SDR (see top row).

If you have any questions please call the National Sales Office hotline on +44 (0) 1246 455998

SDR 44 3 6 17 11 7.3O/D HEAD

SIZEHEAD SIZE

HEADSIZE

HEADSIZE

HEADSIZE

HEADSIZE

110 1(B) 1(A)

15 1(D) 1(C) 1(A)

140 1(A) 1(D) 1(C)

160 (B) (B) (B) (B) (B) 1(D)

180 3(A) (C) (C) (C) (B) (B)

00 3(A) 3(A) 3(A) 3(A) (C) (B)

5 3(B) 3(B) 3(B) 3(B) 3(A) (C)

50 3(C) 3(C) 3(C) 3(C) 3(B) 3(A)

80 4(B) 4(B) 4(B) 3(C) 3(C) 3(B)

315 4(C) 4(C) 4(C) 4(B) 4(A) 3(C)

355 4(D) 4(D) 4(D) 4(C) 4(C) 4(A)

400 4(D) 4(C) 4(B)

450 4(D) 4(D)

Selection chart - internal debeading head size and setting

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The Fusion external debeader is easy to operate. All that is required is to set the debeader to the correct pipe diameter and then after the bead has cooled, simply locate the debeader on the bead and knock into position. Once the debeaders ratchet has been engaged, the debeader works its way round the bend until it has been fully removed.

FEATURES

Simple to useEasily adjusts to pipe diameterDoes not scar the pipeStorage boxRobust, hard working bladesReplacement blades availableNational Grid approved

Fusions external debeader allows:

Quality control procedures from visual bead inspection i.e. bend back testQuality assurance records i.e. archiving beads and data print-out for joint historySlip-lining of old pipes with polyethylene; the removal of the external bead allows a much closer fit

Product Code Range Weight

EXTDB 75-400mm 3kg

EXTDBL 800mm 4kg

EXTDBBLADE Spare blade 75-400mm

40g

EXTERNAL DEBEADERSA simple and effective tool for removing external beads

SPECIFICATION

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PIPE SUPPORT ROLLERS

315 ADJUSTABLE PIPE ROLLER

Suitable for pipe sizes from 63mm up to 315mmLightweight rigid construction for use with automatic and manual machinesPlastic rollers soften impact loading and give a free rolling actionSupplied as a pair80mm (maximum) vertical adjustmentNational Grid approved


Suitable for pipe sizes from 63mm to 400mmLightweight rigid construction for use with automatic and manual machinesMetal rollers contain bearings and give a free rolling actionSupplied as a pair5 stage rapid height adjustment from 118mm to 98mmNational Grid approved


Suitable for pipe sizes from 315 to 630mmIdeal for use with automatic and manual machinesMetal rollers contain bearings to give a free rolling actionSupplied as a pair11 stage height adjustment from approximately 450mm to 850mm National Grid approved

Product Code Description Range Weight

PSROLL315 315 adjustable roller (pair) 63-315mm 4.5kg Each

PSROLL400 400 adjustable roller (pair) 63-400mm 18kg Each

PSROLL630 630 adjustable roller (pair) 315-630mm 5kg Each

SPECIFICATION

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DATA PRINTERA hand-held data printer provides a printed historical joint record containing all the important parameters relating to the jointing process. Using the options presented on the LCD screen of the Fusion butt fusion machine or electrofusion controller, it is easy for the user to select and print the relevant joint records.

FEATURES

Can be used by a supervisor as a silent policeman to ensure pipeline joint integrity.Provides the installer with documentary evidence of good working practices.Helps utilities and contractors to conform to BS EN ISO 9001:000 enabling the operator to demonstrate traceability of parameters for a special process which cannot undergo destructive testing.

STANDARD THERMAL PRINTERFor use with the A60DR, M60DR, AM65 and AM85 electrofusion controllers and the Grey and Gator automatic butt fusion machines (not QBox)

Since the introduction of its very first automatic butt fusion machine, Fusion has recognised the importance of being able to download joint integrity/traceability data. This feature, referred to as Data Retrieval, is available on most Fusion electrofusion controllers and automatic butt fusion machines*. Critical jointing parameters such as pressures, times, voltages and currents, in addition to information such as the time and date of the joint, the operator and the location, are automatically stored as joint records within the internal memory of the machine. At a later stage these joint records can be transferred from the internal memory to other devices for analysis or for safe storage and archiving. With the launch of JointManager, see page , joint records can now be posted to a password protected website. As long as you have an internet connection you can now view, analyse, and share joint data with colleagues and customers 4/7.

Fusion offers four options for downloading joint records: data printer, data transfer lead, Minitran and USB memory stick**.

*Refer to the technical specifications of the various electrofusion and automatic butt fusion machines within this brochure for compatibility.**USB joint download currently only available on the QBOX electrofusion controller.

DATA RETRIEVAL


705856 Printer, lead & roll

705799 Paper roll

705855 Lead (only)

70585 Battery pack

705857 Mains charger

ADVANCED THERMAL PRINTERFor use at present only with the QBox


70589 Printer, lead, roll & charger

705799 Paper roll

705893 Lead (only)

We have set up a Data Transfer Helpline for both new and existing users. Simply phone +44 (0)146 633

Standard Thermal Printer

Advanced Thermal Printer

UNIVERSAL DATA TRANSFER LEAD This lead allows the jointing machine to be connected directly to a free RS3 serial port on a PC that is equipped with the Data Transfer System V software.

FEATURES

Low cost optionSuitable for situations where a portable laptop PC can be used for data collection


70163 Universal data transfer lead

701646 PC USB to RS3 adaptor

SPECIFICATIONS Designed for use with Data Transfer System V software

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MINITRANThe Minitran device allows joint record data to be transferred from a butt fusion machine or electrofusion box to readily available compact flash (CF) memory cards. A PC equipped with the Fusion Data Transfer System software and a compact flash card reader can access the joint record data.

FEATURES

Requires no batteries or separate power supplyCompatible with all Fusion products having the data retrieval feature:

All automatic butt fusion machines including the current Gator range and the earlier grey series*The QBox and most previous electrofusion controllers including A60DR, M60DR, AM65 and AM85

Clear red/green light display for simple useSmall and easily portable (pocket sized)If required, the Data Transfer System V software can be installed on the users PC from the supplied compact flash memory card

SPECIFICATIONS

Uses compact flash (type 1) memory cardsUp to 100,000 joint records can be stored on a 64 megabyte (MB) cardData retention time of up to 10 yearsRequires a PC with a compact flash card reader, alternatively the card reader can be supplied as part of the MINITRANKIT or is available separately.

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* Compatible with grey controllers containing 40k digital PCB software version 096 onwards


MINITRAN Minitran flash memory card data transfer device

(without card reader)

MINITRANKIT Minitran flash memory card data transfer device (with card reader)

70355 Flash memory card

703550 Flash memory card reader

USB MEMORY STICKThe USB memory stick option allows joint record data to be transferred easily from the QBox electrofusion controller.

FEATURES

Requires no batteries, separate power supply or other devices in order to enable easy transfer of joint record dataSimply plugs into the USB port provided on the QBoxPlugs straight into the USB port on a PC for transfer of joint record dataReadily available

SPECIFICATIONS

Up to 100,000 joint records can be stored on a 64 megabyte (MB) deviceFor use with Fusion Data Transfer System softwareFor use with the QBox electrofusion controller


7418 USB memory stick

Minitran

1


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JOINT ANALYSISTraditionally, data retrieved from the internal memory of an electrofusion controller or automatic butt fusion machine has been stored and analysed on the foremans, site agents or contract managers laptop or PC. This option is still available from Fusion in the form of the Data Transfer System V software.

The advent of the internet combined with the move towards partnership working and an increased focus within utilities on joint integrity means that greater flexibility is required with regard to the sharing and analysis of joint records. Fusion has responded to these trends by creating JointManager (see page ) and SiteManager (see page 3).

DATA TRANSFER SYSTEM V2Once digital joint records have been downloaded to a laptop using the Minitran, universal data transfer lead or USB options (see pages 19 and 0) they can be found easily using powerful search facilities and then viewed on screen in various formats. All parameters relating to the jointing process are available. Visual analysis of important information such as joint integrity and operator performance is possible using pie charts and graphs. The information is invaluable when assessing costs and training needs. All information is just a few clicks away and yet is stored in total security.


70135 Data transfer system software version .0 on CD

70141 Data transfer system software version .0 kit

including CD and universal data transfer lead

FEATURES

Helps utilities and contractors to conform to BS EN ISO 9001:000 enabling the operator to demonstrate traceability of parameters for a special process which cannot undergo destructive testing.The software is compatible with PCs running Windows 98, NT, 000 and XP operating systemsProvides a means of evaluating overall quality of newly joined pipe:

Highlights deviations from agreed proceduresRecords performance levels of those operating the equipmentThe jointing equipment itself can be monitored thus providing continuous feedback of machine performance

Chart facility produces a clear graphical record of error conditions, pipe usage etcCompatible with all Fusion products having the Data Retrieval feature:

All automatic butt fusion machines including the current Gator range and the earlier grey series*The QBox and most previous electrofusion controllers including A60DR(CE), M60DR(CE), AM65(CE) and AM85CE

* Compatible with grey controllers containing 40k digital PCB software version 096 onwards

Call the Data Transfer Hotline on +44 (0)1246 262323 if in any doubt as to the compatibility of your Fusion product with the Data Transfer System V software.

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JOINT MANAGERIn the 1990s, Fusion pioneered data transfer software which allowed joint data to be electronically downloaded and stored on a laptop or PC for analysis and review.

Today, JointManager enables you to electronically send your encrypted joint records to a secure password protected server which you can access any time of day or night via the JointManager web portal. The flexibility of the JointManager database structure means you can undertake a far more rigorous analysis of your joint data than was possible with the previous Data Transfer System V software. Furthermore, you can monitor joint integrity trends over multiple projects: its the ideal tool for identifying deviations from agreed procedures over time, the performance of those using the machines, even the performance of the machine itself.

There is a growing recognition within utilities of the operational and financial value of ensuring joint integrity. JointManagers use of the internet means that joint records and analysis can be shared between contractors, consultants and utility managers.

FEATURESIn addition to the functionality provided by the V software, JointManager has many additional features:

Multi-lingual support including Chinese; language can be changed quickly and easily when necessaryModern user interface simplifies all operationsImproved and automated data sorting and storage facilities make jointing information easier to find, view, analyse and exportThe data is stored on a secure server, which can be accessed using the internet at anytime from anywhere in the worldImproved output facilities including the standard .pdf formatImproved reporting facilities that can be personalised as desiredFuture add-ons will provide specific program functionality, allowing the user to tailor the software exactly as requiredSoftware updates handled automatically over the internet

Screen shots for illustrative purposes only

jointmanager

jointmanager

3


ASSET INTEGRITYJoint integrity is a critical element in a portfolio of variables which, taken collectively, can be described as asset integrity.

Utilities spend a long time designing, specifying, and procuring underground infrastructure. There is a high degree of control and scrutiny at each stage. Once the infrastructure is in place, utilities are using telemetry and modelling to optimise the performance of the asset over its lifetime.

The weakest link in terms of control is, ironically, the most important: installation.

The installation phase of underground infrastructure is different from the design and management phases in two key areas. Firstly, front line responsibility often transfers from the utility to the contractor, or to a partnership arrangement. Secondly, the primary location is the site rather than the utility office. Not only is out of sight often out of mind, frequently out of sight means out of control.

SITE MANAGER

Ass

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Site

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Developed by Fusion, SiteManager plugs the information and communications gap that exists between a site and the managers office, and between contractor and client. SiteManager uses rugged handheld devices to collect a huge array of data: photographs, GPS locations, barcodes, signatures, joint records, HSEQ audits, TMA feedback to name just a few.

The collected data is validated, encrypted and transmitted back to the SiteManager website using mobile telephony. At this point the data is transformed into information in a variety of formats - graphs, reports, variance analysis etc - which are automatically communicated to authorised recipients via email or SMS: in real time. Management information you can actually use to manage!

How to turn this information into insight? One option is to filter the SiteManager information through the experienced and analytical mind of the utility or construction manager, and for them to initiate actions based on what they find. A second option is to use the services of Fusion Group company, Insite.

Insites experienced utility specialists can review information as it is received and respond accordingly; this could mean simply contacting site and fine tuning procedures, or alerting specialists in areas such as mapping, joint failure, training, and leak detection. With Insite, out of sight no longer means out of control.

To discuss JointManager, SiteManager and Insite in more detail, or for a demonstration, please contact Steve Hamshaw on 0146-6787 or [email protected]

WEB PORTAL

GPS

Forms

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sitemanager

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ELECTROFUSION - WHAT DO I NEED?

A basic electrofusion kit for jointing polyethylene (PE) pipes should include:-

An automatic or manual control box with appropriate leadsGenerator Pipe cutter Pipe scraper Restraining, aligning and insertion equipment Indelible marker pen

Optional extras could include:

Data retrieval options Barcode scanner

New to electrofusion? Fusion Group can provide training on all of our products tailored to your specific needs. Contact the Equipment Office on +44 (0) 146 68666 for more details.

Fusion has also produced a Good Guide to Electrofusion which takes you through the process step-by-step. You can download a copy free of charge from our website at www.fusiongroup.com

Details of Fusions comprehensive range of electrofusion fittings are given in the fittings catalogue. To obtain a copy simply call your nearest distributor or download a copy free of charge from our website at www.fusiongroup.com

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Good Guide to Butt Fusion and Electrofusion Jointing

PRODUCT DETAILS

Electrofusion FittingsProduct Guide

ItemMachine Description

Page(s)Manual (Fusamatic) Automatic

Barcode Data Retrieval

Q Box 110V Pages 7-8Q Box 110V Barcode Pages 7-8Q Box 0/30V Pages 7-8Q Box 0/30V Barcode Pages 7-8Standard A 0/30V Box Page 9Standard M 0/30V Box Page 9E

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THE GOOD GUIDE TO: ELECTROFUSION

Dos and DontsPRE JOINTING CHECKS

Use equipment that is clean, in good condition, regularly maintained and within required calibration/service.

Ensure that cutters/blades and scrapers are clean and in good condition.

Mechanical scrapers must be used wherever possible.

Check that restraining clamps are in good condition.

Check that you have somewhere clean and dry to place tools and equipment during the electrofusion process.

Do not start the jointing process unless it can be completed in one go.

DOS

Understand the principles of electrofusion (refer to pipe manufacturers details in van pack if necessary).

Ensure all fusion indicators have risen, if not cut out and make new weld.

Use a shelter and ground sheet, both in dry and wet conditions, to minimise contamination.

Use pipe end covers wherever possible.

Always enter your details into the electrofusion control box if the box requests it; your operator code and job code must be entered to allow full traceability.

Always use clamps for alignment/restraining/ re-rounding.

Ensure control box voltage is compatible with fitting.

Ensure pipe and fittings to be jointed are compatible with each other.

Cut pipe ends square for all electrofusion socket fittings.

Fully scrape pipe and/or spigot surfaces. (Secura-Line pipes need not be scraped prior to electrofusion if outer skin has been freshly peeled and the core pipe is pristine. Should the peeled pipe ends become contaminated then they should be treated in the same way as standard PE pipe).

Keep scraped pipe and/or spigot surfaces and fittings clean.

Assemble joint and fuse immediately following scraping the pipe.

If Fusion automatic fittings and boxes are being used, connect the red lead to the fitting terminal with the red pin and the black lead to the plain pin.

In all cases check the fusion time displayed by the control box matches the fusion time on the fitting. If different do not continue to weld, replace with a new bagged fitting or enter fitting time manually.

Ensure correct fusion and cooling times are observed and adhered to.

Drilling/tapping through fitting/pipe should only be carried out following the required quality inspections and pressure testing.

Always ensure you mark the completed joint with the number issued from the electrofusion control box, along with the date. Again, this is imperative for full traceability.

DONTS

Do not start any electrofusion joint unless it can be completed without interruption.

Do not use an electrofusion box within an excavation.

Under no circumstances should an attempt be made to carry out a second fusion cycle on any fitting. This is a WIS 4-3-08 specification and must be adhered to.

Incomplete, interrupted, failed or aborted fittings should ALWAYS be cut out, bagged and numbered with corresponding joint number for submission to the supervisor for inspection.

(CONTINUED....)

6

THE GOOD GUIDE TO: ELECTROFUSION

Dos and DontsDONTS (...CONTINUED)

Do not use dirty or contaminated fittings, or those from split or torn bags, or touch prepared surfaces.

Do not leave fittings out of their protective bags or remove them from bags until immediately before use.

Do not allow prepared fusion/jointing surfaces to become wet or damp.

Do not remove clamps from fitting until cooling time has elapsed.

Do not remove integral cutter from the stack/saddle once the main has been drilled.

IF EVER IN DOUBT - CUT IT OUT

THE USE OF WET WIPES

The preferred position is to make electrofusion joints without the use of Wet Wipes. This guidance pertains as long as the pipes are freshly scraped, the fitting has just been debagged and the assembly and fusion of the joint follows immediately.

If any deviation from the above occurs, which may result in contamination of either the scraped pipe or the debagged fitting, then prescribed Wet Wipes shall be used. Separate fresh Wet Wipes shall be used for the scraped pipes and the debagged fitting if both are contaminated. Whether wiping both scraped pipe or fitting or just one of them, wiped surfaces must be allowed to visibly dry (do not touch the wet surface), then the joint assembled and fused. Failure to allow the jointing surfaces to visually dry will increase the risk of voids at the weld interface.

N.B. In butt fusion jointing Wet Wipes are not used for cleaning pipes that have already been machined/trimmed.

HEALTH AND SAFETY

Fusion Provida make every effort in the design and manufacture of its pipes, fittings and equipment to ensure safety in use. The following precautions are however worth bearing in mind:

Never allow hot polyethylene to come into contact with the skin. In such an event cold water should be used to cool the affected area. Expert medical advice should be sought.

Under no circumstances should any attempt be made to remove any material that becomes stuck on the skin without medical supervision, as this would risk a more serious injury.

Heavy pipes, fittings and equipment should not be handled without assistance or mechanical aid. The requirements of manual handing legislation should be adhered to.

Health and safety regulations insist upon the wearing of personal protective equipment such as gloves, safety glasses and safety boots whilst carrying out electrofusion joints.

Care should be exercised, by taking normal precautions, when using electrical equipment on site, particularly in wet conditions.

Normal precautions should be observed when handling electrical equipment and, for safety reasons, all 110v portable generator sets should be centre tapped for site use +55/0/-55 volts.

ALWAYS REMEMBER THAT ALL JOINT RECORDS ARE AUTOMATICALLY STORED AND SHOULD BE DOWNLOADED ON A REGULAR BASIS TO ALLOW FULL TRACEABILITY AND INTEGRITY OF WORKMANSHIP.

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QBOX(ELECTROFUSION CONTROL BOXES)

FEATURES

Largest, brightest screen in its classImproved user interface with helpful on-screen promptsAutomatic contrast adjustment of the screenMulti-lingual display; the language can be changed at the touch of a buttonConvenient on screen display at all times of

remaining joint record memory capacitytime until next serviceinput supply voltagetime and date

Well specified control system allowing for future upgrades and improvementsJoint record data is stored in internal memory and is automatically backed up to a removable SD card for complete securityCompatible with the Data Transfer System software; joint record data can easily be downloaded to a readily available USB memory stick for the transfer of data to PCJoint records can be reviewed quickly on screenFusions unique touch-key technology is available on 110V UK control boxesCount-up timer at the end of jointing allows the cooling time to be monitoredRobust construction employing high quality die-cast aluminium enclosure and integrated heat-sinkIP54 rated to EN6059 preventing ingress of water and dirtImproved performance allows use with larger fittingsPlus all the existing functions of a Fusion control box

IMPROVED MAINTENANCE AND SERVICING

Quick and easy calibration using the keypadIntelligent design allowing fascia screen and keypad to be replaced quickly and independently, reducing potential maintenance costsThe operating software upgrades can be updated quickly and easily via a USB memory stickImproved lead end assemblies and sense pin designed for strength, durability and ease of maintenanceInput and output cables are more flexible and user friendlyStandard box can be upgraded with a barcode reader if required.

Dos and Donts

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QBOX(ELECTROFUSION CONTROL BOXES)

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Box

Description QBOX110 QBOX110BC QBOX0E QBOX0BCE

Input supply voltage (Vac) 97-150V 97-150V 187-65V 187-65V

Frequency (Hz) 40-70 40-70 40-70 40-70

Max output current (A) 80 80 80 80

Maximum output power (kW) 3.0 3.0 3.0 3.0

Recommended minimum generator size for 40V, 60A output* (kVA)

3.75 3.75 3.75 3.75

Recommended minimum generator size for 40V, 80A output* (kVA)

5.00 5.00 5.00 5.00

Operating temperature (deg C) -10 to +50 -10 to +50 -10 to +50 -10 to +50

Environmental protection (IP) IP54 IP54 IP54 IP54

Compatable with manual fittings Yes Yes Yes Yes

Compatable with Fusamatic fittings Yes Yes Yes Yes

Bar code reader No Yes No Yes

Output voltage (V) Fixed: 39.5 Variable: 10-48 Fixed: 39.5 Variable: 10-48

Fuse time(s) 10-3500 10-3500 10-3500 10-3500

Safety frame Yes Yes Yes Yes

Detachable output cable Yes Yes Yes Yes

Weight excluding output cable (kg) 3 3 1.5 1.5

Output cable length (m) 3. 3. 3. 3.

Input cable length (m) 6 6 3 3

Input plug rating (A) 3 3 16 16

Data memory (number of joints) up to 000 up to 000 up to 000 up to 000

Data transfer methods Direct to PC using the universal data transfer lead, via the MiniTran, via the USB memory stick

Memory back up SD Card Yes Yes Yes Yes

Dimensions (including frame) (mm) 300W x 90D x 430H



QBOX0E 0/30V automatic electrofusion controller

QBOX110 110V automatic electrofusion controller

QBOX0BCE 0/30V automatic/barcode electrofusion controller

QBOX110BC 110V automatic/barcode electrofusion controller

QBOX0BC10E 0V/30v automatic/barcode electrofusion controller (with 10 metre output lead)

QBOX010E 0/30V automatic electrofusion controller (with 10 metre output lead)

7413 QBOX protective lid kit - for parallel frame type

7418 USB memory stick

* E denotes plug type E = 3 Pin Blue G = 2 Pin Black

* The minimum values shown in the table will guarantee correct operation of the control box when supplying the specified current to the electrofusion fitting. It may be possible to use a generator of a smaller size when employing the control box for service connection work.The kW rating of the generator must also be considered; contact your nearest Fusion representative for advice on generator selection if in any doubt.

9


STANDARD ABOX & STANDARD MBOX(ELECTROFUSION CONTROL BOXES)

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STANDARD ABOX FEATURES

Designed for use with Fusions Fusamatic range of automatic recognition fittings0V/30V operationSimple user interface with only two buttonsFull microprocessor control and verification of jointing processTwo row LCD displayAvailable in many languages

STANDARD MBOX FEATURES

Designed for use with manual fittings0V/30V operationSimple user interface with four buttonsFull microprocessor control and verification of jointing processTwo row LCD displayAvailable in many languages

Product Code

Description

STDBOXA 0/30V automatic (Fusamatic) electrofusion controller

STDBOXM 0/30V manual electrofusion controller

MACHINE SPECIFICATIONDescription STANDARD A STANDARD M

Input supply voltage (Vac) 195-60 195-60

Frequency (Hz) 40-70 40-70

Max output current (A) 60 60

Output voltage; typical (V) 39.5 39.5

Output voltage; min/max (V) 38.8/40. 38.8/40.

Recommended minimum generator size for 60A output* (kVA)

3. 3.

Operating temperature (deg C) -10 to +40 -10 to +40

Environmental protection (IP) IP54 IP54

Compatable with manual fittings No Yes

Compatable with Fusamatic fittings Yes No

Fuse time(s) 0-900 10-3000

Data memory/retrieval/printout None/Unavailable

Safety frame Yes Yes

Output lead type Fixed Fixed

Weight including cables (kg) .5 .5

Output cable length (m) 3 3

Input cable length (m) 3 3

Input plug rating (A) 16 16

Dimensions (including frame) (mm) 475(W) x 375(L) x 65(H)

* The minimum values shown in the table will guarantee correct operation of the control box when supplying the specified current to the electrofusion fitting. It may be possible to use a generator of a smaller size when employing the control box for service connection work.The kW rating of the generator must also be considered; contact your nearest Fusion representative for advice on generator selection if in any doubt.

Designed as a basic specification box for pipeline jointing where accurate microprocessor control is a must but advanced functionality such as data retrieval is not required.

30

Multi Scrape is a versatile pipe scraper designed specifically with coiled pipe in mind. Mandrels keep the pipe end straight and a spring loaded blade ensures that the optimum cut is achieved.

FEATURES

Scrapes 0-63mm pipe with one toolRobust and lightweight construction Easy to useHardened steel blade, indexable and replaceablePrecision blade ensures a consistent depth of cutSprung loaded arm ensures an consistant scrape, even on coiled and oval pipeExpandable mandrels aid pipe re-rounding and cover a wide variety of pipe sizes and SDRs to be scrapedSwarf easily removed without touching the freshly scraped pipeSupplied in a robust carry case complete with all mandrelsTool also supplied for individual sizes if other mandrels not requiredNational Grid approved

MULTI SCRAPE


MULTISCRAPE Tool only

MULTISCRAPEKIT Tool including complete set of mandrels and spare blade in case

MULTISCRKITUK Tool including 63mm SDR11/3mm/5mm mandrels only in case

MULTISCRKITEM Tool including 0mm/5mm/small expanding/medium expanding/large expanding mandrels in case

35571 0mm solid mandrel




35575 50mm SDR11 solid mandrel




35559 Spare blade

90 Case

35794 Small expanding mandrel covers 3mm and 40mm

35795 Medium expanding mandrel covers 50mm (all SDRs)

35796 Large expanding mandrel covers 63mm (all SDRs)Ele

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Diameter Range SDR Range Case Dimensions Weight (Complete kit)

0, 5, 3, 40, 50, 55 and 63mm 11, 17 75 x 5 x 90mm .5kg

SPECIFICATIONS

MULTISCRKITEM - Multi Scrape

Expandable mandrel Multi Scrape in use

31


HAND SCRAPERS(SCRAPERS 20MM+)

Hand scrapers are used for scraping pipe areas prior to the electrofusion of couplers, reducers, branch saddles and tapping tees. The area for scraping should be outlined with marker pen and, with good even strokes of the scraper along the length of the pipe, an even layer of approx 0.mm of the surface layer should be removed. The operator should be looking for a clean even scrape of the entire jointing area.

FEATURES

Easy to useRobust plastic handle constructionHardened steel blades (4 cutting edges)Replacement blades available National Grid approved

THE UNIVERSAL SCRAPER(SCRAPERS 63-250MM)

The Universal Scraper provides a convenient means of preparing pipe ends prior to electrofusion jointing. It can operate on all pipe diameters and commonly used SDR sizes from 63mm to 50mm inclusive and can be used on coiled pipe.

FEATURES

Correct length of scrape is pre-setFixed, serrated blade driven around the pipe by a splined shaftRatchet actionInternal roller action holds the blade against the pipeThe adjustment knob caters for the variation in wall thickness and pressure ratingsCarry case, spare blade and cleaning brushNational Grid approved

Product Code Description Weight

HARRIS Harris 1.5 0.1kg

HARRISLGE Harris .5 0.1kg

601 Harris 1.5 spare blade N/A

6033 Harris .5 spare blade N/A

Product Code Description/Range Weight

UNISCRP 63mm-50mm 4.5Kg (incl case)

370300 Spare blade N/AEl

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UNIPREP SCRAPER(SCRAPERS 90-500MM)

Uniprep scrapers are robust tools and can be used for preparing pipe ends prior to electrofusion on pipe sizes 90-500mm. Exact size ranges are given in the table below.

FEATURES

Maintains mechanical scraping across the whole joint areaFaster scraping actionHardened bladeControlled depth of cutNational Grid approved

PRODUCT CODE DESCRIPTION/RANGE WEIGHT

UNIPREP5 63-5mm 3kg

UNIPREP50 90-50mm 3kg

UNIPREP400 110-400mm 3.5kg

UNIPREP500 15-500mm 4kg

UNIPREP Blade N/A

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MULTI-CLAMPThe new Multi-Clamp kit has been specifically re-designed for easier alignment and restraint of electrofusion fittings as a result of customers requests for a lighter, more flexible multi-clamp to suit narrow trenching techniques.

FEATURES

Promotes full rerounding and restraint during electrofusionTop clamp is removable via a hinge pin to allow use in narrow trenchesThe new dovetail assembly allows complete rotation through 360 to suit any pipe and fittings configuration (large diameter tees require extra base, ring and liners)Extruded lightweight baseNational Grid approved

Product Code Weight

MCKIT180B 0.75kg

1 x Carrying bag

2 x Basic 180mm rings (no bosses)

1 x 600mm base

4 x 180mm x 125mm liners segments



2 x Dovetail slide blocks

1 x Allen key

Product Code Weight

MCKIT180 30.5kg

1 x Plastic container

2 x 180mm rings





2 x 460mm bases

1 x Allen key

1 x Spanner

1 x T connector

Product Code Weight

MCKIT180DL 30.5kg

1 x Plastic Container

2 x Basic 180mm rings

2 x Bossed Rings





2 x 460mm bases

1x Allen key

1 x T connector

Product Code

Description

1390 180mm ring

13000 460mm base

148500 600mm base

11987 180mm ring with boss

541 180mm x 160mm liner segments







SAW Saw

SGUIDE Saw guide

33469 Hinge pin and wire

33470 Locking handle with screw (for base)

169 45 convertor

BASIC UNIVERSAL DELUXE

OPTIONAL EXTRAS & SPARES

Saw guide

T connector

Saw

Multi - Clamp with bossed rings

45 convertor

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MULTI-CLAMP

APPLICATION AND USAGE

/2 RINGS)

/2 RINGS)

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LITE SERVICE CLAMPSIntroducing a new range of size specific pipe clamps designed for use on service connections where space is at a premium. The new Lite range of clamps comprises a 90 elbow clamp in sizes 0mm, 5mm or 3mm and a multiclamp that encompasses 90, 45 and straight connections, again in either 0mm, 5mm or 3mm.

FEATURES

Extremely light; minimised residual loading on pipe during clampingSimple and compact design for use in the tightest working spacesEconomical and robustManufactured from a tough engineering plasticNational Grid approved

VERSACLAMP

SPECIFICATIONS


VERSACLAMP0 0mm multi angled clamp 0.180kg



ELBOW CLAMPSA very simple hand tool for clamping 0, 5 and 3mm service pipe when fusing 90 elbows giving stress free joints


ELBOWCLAMP0 Elbow clamp 0mm 0.1kg



SPECIFICATIONS

FEATURES

Extremely light; minimised residual loading on pipe during clampingSimple and compact design for use in the tightest working spacesEconomical and robustManufactured from a tough engineering plasticNational Grid approved

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The mini and maxi clamps are designed to retain and align pipe and fittings for service connections during the electrofusion process.

The mini clamp is suitable for pipe sizes 0, 5 and 3mm and the maxi clamp 40, 50, 55 and 63mm.

FEATURES

Interchangeable armsReducers, couplers & tapping tee outlets can be accommodatedQuick tightening operationLightweight and easy to useRobust constructionPromotes re-rounding and restraint during electrofusionNational Grid approved

Easy to use clamp for electrofusion fittings 0 to 75mm. Can be used for couplers, reducers, end caps, equal tees, 45 & 90 elbows.

FEATURES

Accepts all types of electrofusion fittingsAligns, restrains and promotes re-rounding of the pipe to prevent movement of the fitting during fusion and coolingLightweight and easy to useExceedingly strongMade from a tough engineering plastic called NorylAll nuts and adjustments are fully captive and therefore cannot be lostNational Grid approved


MINICLAMP 0, 5 & 3mm 1kg

MAXI40 40mm 1.3kg

MAXI50 50mm 1.3kg

MAXI55 55mm 1.3kg

MAXI63 63mm 1.3kg Ele

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MINIPOSI CouplersReducersEnd caps

Equal tees45 degree elbows90 degree elbows

0mm5mm3mm40mm

0.5kg

MAXIPOSI CouplersReducersEnd caps


3mm40mm50mm63mm

0.9kg

MAXIPOSI75 CouplersReducersEnd caps


40mm55mm63mm75mm

0.9kg

MINI POSI AND MAXI POSI CLAMPS

SPECIFICATIONS

MINI AND MAXI CLAMPS

SPECIFICATIONS

Note: Units are not suitable for use on 45 degree or 90 degree elbows when used on tapping tee outlets.

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ALIGNMENT CLAMPS

FEATURES

Fixed clampsRobust constructionHinged with pins for ease of pipe positioning in trench - allows for narrow trenching techniquesLightweight and portableOptional threaded bosses available for branching drill connections for under pressure drilling (product code: 34446) (MC50 only)Offers full rerounding and restraint of pipe and fitting during welding

Product Code Weight

MC50 13.5kg

MC315 9kg

MC355 33kg

Part Code Description Weight

1707 Liner 50x180 (ring) ( required per tool) Split ring set allowing MC50 to clamp 180 pipe

9.0kg


6.7kg


3.5kg

BFL31500 Liner set (8 segments) allowing MC315 to clamp 00mm pipe 7.5kg

BFL31550 Liner set (8 segments) allowing MC315 to clamp 50mm pipe 8kg

BFL31580 Liner set (8 segments) allowing MC315 to clamp 80mm pipe 7kg

11615 Liner 355x315 (ring) (4 required per tool)Split ring set allowing MC355 to clamp 315 pipe

4.5kg

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SPECIFICATIONS

This type of clamp is an aid to ensure correct alignment of pipe and large diameter couplers during the electrofusion process and during the cooling period. It is available in 3 basic sizes for 50mm, 315mm and 355mm pipe. Each tool can be linered down as detailed in the table below.

OPTIONAL EXTRAS & SPARES

315mm Alignment Clamp

250mm Alignment Clamp

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G CLAMPSG Clamps are used in the installation of top loading (also known as stack loading) electrofusion branch saddles and tapping tees.

FEATURES

Suitable for all manufacturers top loading fittings that comply with GIS PL/E Part 4Load indicator gives visual indication of correct force application between fitting and pipe thereby ensuring joint integrityLoad screw totally isolated from load indicator mechanism, thus not affected by use

Note: Econ Range G Clamps do not require an adaptor to work with Fusions Multiseal tapping tees


GCLAMP 63-50mm 5kg

GCLAMPE 63-315mm 8kg

GCLAMPSL 63-400mm 10.5kg

Note: All Standard Range G Clamps are supplied with an adaptor for use with Fusions unique Multiseal tapping tees. To order additional adaptors use the part code GTOOLADAPT


GCLAMP.ECON( piece bar)

63-400mm 5.5kg

GCLAMP.ECON50 63-50mm 5kg

GCLAMP.ECON400(1 piece bar)

63-400mm 7kg

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THE STANDARD RANGEAvailable in three sizes: 63-50mm, 63 - 315mm, 63 - 400mm.

All the above G Clamps have telescopic range

SPECIFICATIONS

THE ECONOMY RANGEA lightweight alternative to the Standard G Clamp system, constructed from corrosion resistant materials.

Swivel foot centralises and accommodates varying pipe positions

SPECIFICATIONS

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CUTKEY1 Universal tapping tee cutter key (with cutter key and wrench)

0.6kg

1681 Cutter key 3mm with thread follower(not for use with Multiseal)

0.5kg

1681B Cutter key 3mm extended shaft with thread follower

(not for use with Multiseal)

0.65kg

353600 Cutter key 63mm with thread follower(not for use with Multiseal)

0.9kg

CUTTERKEYEXL Universal tapping tee cutter keyextended length - 1000mm

1.5kg

CUTTER KEY

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TEST CAP

A range of drive key tools for service/tapping tee integral cutters with 1mm hexagonal drives (as per UK WIS and GIS specifications).National Grid approved.

A range of reusable caps for the pressure testing of Fusion manufactured service/tapping tee fittings.National Grid approved.


3864 63mm test cap(not for use with Multiseal)

0.1

3865 3mm test cap(not for use with Multiseal)

0.1

3463 3mm Multiseal test cap 0.1

34571 63mm Multiseal test cap 0.1

867 3mm Aluminium HD Multiseal test cap 0.

869 63mm Aluminium HD Multiseal test cap 0.4

SPECIFICATIONS

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32mm 63mm 63mm Aluminium

26181 - Cutter key 32mm

CUTKEY12 - Universal tapping tee cutter key

CUTTERKEYEXL - Universal tapping tee cutter key extended length

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Pulls lengths of pipe into position with minimal effort on the part of the operator using a simple but ingenious ratchet system. For use on pipe ranging from 40-00mm diameter.

FEATURES

Ratchet handle includedLightweightFast acting tug and tension strapsWorks in all positions around the jointCompact designNo liners requiredIdeal for use with Ping seal socket fittingsNational Grid approved

TITAN 500(STRAP CLAMP 160-500MM)

The Strap Clamp Titan is the Daddy of the range. It is capable of pulling 1m lengths of pipe into position with minimal effort on the part of the operator using a simple but ingenious ratchet system.

FEATURES

Ratchet handle includedFast acting tug and tension strapsWorks in all positions around the jointCompact designNo liners requiredNational Grid approved


SC00T Straight ratchet runner bar with 4 clamps 40-00mm 6.5kg

TITAN 200(STRAP CLAMP 40-200MM)


SC500T Straight ratchet runner bar with 4 clamps 160-500mm 0kg

SPECIFICATIONS

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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For use on pipe ranging from 40mm to 00mm diameter. A centrally located adjustable knuckle allows the SC00--K to be used for elbows and reducers as well as couplers.

FEATURES

LightweightFast acting tug and tension strapsWorks above, below or alongside the jointCompact designNo liners required

STRAP CLAMP 200 KNUCKLE (STRAP CLAMP KNUCKLE 40-200mm)


SC00--K Knuckle bar with clamps 40-00mm .7Kg

SC00--K-4 Knuckle bar with 4 clamps 40-00mm 4.6Kg

T-ADAPTORA smart add-on tool allowing Strap Clamps to be used for clamping tees. The T-Adaptor can be used on pipe ranging from 40mm to 00mm.

To use the T-Adaptor a further V-block clamp needs to be purchased.


SC00ADT Strap clamp T-Adaptor 40-00mm 0.3Kg

34989 V block clamp assembly 40-00mm 0.6Kg

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SPECIFICATIONS

SPECIFICATIONS

Elbow

SC200-2-K

Reducer SC200-2-K-4

SC200-2-K with T-Adaptor

V-block

T-Adaptor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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For use on pipe ranging from 40mm to 00mm diameter

FEATURES

LightweightFast acting tug and tension strapsWorks above, below or alongside the jointCompact designNo liners requiredNational Grid approved


SC00--S Straight runner bar with clamps 40-00mm .5kg

SC00--S-4 Straight runner bar with 4 clamps 40-00mm 4.6kg

STRAP CLAMP 200 STRAIGHT (STRAP CLAMPS STRAIGHT 40-200MM)

STRAP CLAMP 500 STRAIGHT(STRAP CLAMPS STRAIGHT 160-500MM)

Accommodating pipes between 160 and 500mm, the SC500 is the SC00s big brother.National Grid approved.


SC500 Plain runner bar with clamps 160-500mm 8kg

1799 V-block clamp assembly 160-500mm 1.5kg

Note: To use the Strap Clamp 200 Straight to clamp tees, a T-Adaptor is required - see previous page for details

SPECIFICATIONS

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SC200-2-S

SC500

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POWERCLAMP - 125mm & 180mmIntroducing the Powerclamp hydraulic rerounding tool. Powerclamp has been developed by Fusion and the water companies as a result of on site trials to help combat pipe ovality on coil installations.

FEATURES

Produces stress free electrofusion jointsProvides rerounding force from sides where the ovality is worstLightweight - single person liftMechanical stops prevent over rerounding and pipe damageIncreases on site productivityMinimal effort required from operatorTop loading for easy in trench useFast acting hydraulic pump speeds up the process of using pipe insertsLighweight polyethylene liners to increase the tools rangeCan be lined down to 110mm and 160mm respectivelyNational Grid approved

Product Code Diameter Range

SDR Range

Operating Temperature

Tool Dimensions

Weight

POWERCLAMP15 15 & 110mm All -10 C to +40 C 55(W)X360(H)X15(L)mmHydraulic Rerounder

410(L) including alignment kit

14kg Hydraulic Rerounder

5kg alignment kit

10kg hand pump

POWERCLAMP180 180 & 160mm All -10 C to +40 C 350(W)x500(H)x00(L)mm Hydraulic Rerounder

750(L) including alignment kit

17.5kg Hydraulic rerounder

6.5kg alignment kit

10kg hand pump

SPECIFICATIONS

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Designed for rerounding pipes after squeeze off has been applied. The range covers 50-50mm polyethylene pipes.

FEATURES

Designed to be left permanently underground if requiredTwo separate half shells brought together by extended nutsSteel unitDiagonal pattern tightening actionThe longer the clamp is left in position the better the rerounding effect National Grid approved.

REROUNDING/POST SQUEEZE-OFF CLAMPS

REROUNDING TOOLSFor rerounding polyethylene coiled or oval pipe prior to electrofusion. See table for available size range.National Grid approved.


RRC50 50mm .9kg

RRC63 63mm 3kg

RRC75 75mm 3.5kg

RRC90 90mm 3.5kg

RRC110 110mm 5.75kg

RRC15 15mm 5.5kg

RRC140 140mm 5.5kg

RRC160 160mm 7.5kg

RRC180 180mm 6.75kg

RRC00 00mm 9.5kg

RRC5 5mm 11.5kg

RRC50 50mm 1kg


RRT16 16mm 0.4kg

RRT0 0mm 0.5kg

RRT5 5mm 0.5kg

RRT3 3mm 0.5kg

RRT40 40mm 1.5kg

RRT50 50mm 1.5kg

RRT55 55mm 1.5kg

RRT63 63mm 1.5kg

RRT75 75mm 1.5kg

RRT90 90mm 1.5kg

RRT110 110mm .0kg

RRT15 15mm .0kg

RRT160 160mm .5kg

RRT180 180mm 3.0kg

RRT00 00mm 3.0kg

RRT5 5mm 3.0kg

RRT50 50mm 3.0kg

SPECIFICATIONS

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .For a unique rerounding solution see the Powerclamp on Page 4

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The Mini Squeeze Tool is designed solely for SDR11 service pipes in the ranges 16 to 3mm.

FEATURES

Compact, robust designEasy to useUnique design incorporates built-in safety stops to prevent damage to the pipeNational Grid approved

MINI SQUEEZE TOOL(SQUEEZE TOOLS 16-32mm)

SERVICE SQUEEZE TOOL 63(SQUEEZE TOOLS 16-63mm)

The Service Squeeze Tool is for stopping on both metric and imperial sizes of pipe. It may be used on 16, 0, 5, 3, 40, 50 and 63mm metric pipes or on 3/4, 1 or imperial pipes (imperial stops sold separately).

FEATURES

A compact unit fitted with squeeze limit platesThe limit plates prevent damage to the pipeSqueeze-off is affected by turning the handle in a clockwise directionNational Grid approved

(SQUEEZE TOOLS 63-125mm)

Mechanical Squeeze Off Tool for thin walled pipe 63-15mm diameter (SDR 11 63/90mm) (SDR17.6 90/110/15mm)

FEATURES

A compact unit fitted with squeeze limit platesThe limit plates prevent damage to the pipeSqueeze-off is affected by turning the handle in a clockwise directionNational Grid approved


SQT3 16 to 3mm Mini Squeeze Tool 1kg

SQT63 16 to 63mm Mini Squeeze Tool (UK) 6kg

SQT63X10 16 to 63mm Mini Squeeze Tool (Exp) 6kg

SQT15M 63-15mm Squeeze Tool 9.0kg

Note: To comply with best practice, rerounding clamps should be used post squeeze-off.

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MECHANICAL SQUEEZE OFF TOOL

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Product Code SDR Rating Diameter Weight

SQT15(1 set end gauges)

11 63, 75, 90, 110, 1519kg

17 / 17.6 90, 110, 15

SQT15UK( sets end gauges)

11 63, 75, 90, 110, 15, 3, 4

19kg17 / 17.6 90, 110, 15

1 75, 90, 110, 15

3574 Replacement / spare jack - 10 tonne - tested

Hydraulically operated squeeze tool for use on pipe sizes between 63mm and 15mm designed with compact trenches in mind.

FEATURES

Full stroke hydraulic unitUltra compact frame designMechanical safety stops prevent creep and permit controlled releaseNational Grid approved

125 MAINS SQUEEZE TOOL(SQUEEZE TOOLS 63-125mm)


The Mains Squeeze Tool is used as a flow stop on both metric or imperial sizes of pipe. The tool comes with a variety of end gauges for 63 to 00mm and various SDR ratings.

FEATURES

Full stoke hydraulic unit Metric or imperial limit platesMechanical safety stops prevent creep and permit controlled release Springs to return jack to park position after squeeze offIntegral safety relief valveStandard export tool comes complete with sets of end gauges for 63mm - 00mm SDR11 and 17If SDR 1 end gauges are required please order SQT00UKNational Grid approved

PRODUCT CODE DESCRIPTION WEIGHT

SQT00UK 00mm Squeeze Tool with stops for SDR 11, 17 and SDR1 39kg

SQT00 00mm Squeeze Tool with stops for SDR11 and 17 39kg

35303 Replacement / Spare Jack - 15 Tonne - Tested 10kg

33969 Dual marked end gauges up to 180mm - SDR11, 17.6 are available if required

0.6kg

Note: For correct site practice, rerounding clamps should be used after squeeze off is completed.

SPECIFICATIONS

SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SQT250A / SQT250AECONThe 50 Mains Squeeze Tool can be used for stopping-off on 180 to 50mm pipe. When a pipe has been squeezed-off the hydraulic cylinder frame can be removed leaving only the beams and stops in-situ (see diagrams).

The A frame design is very lightweight and folds compactly with handles and lifting points for ease of transportation compared with more traditional squeeze-off equipment.

The standard A frame tool (SQT50A) is supplied with 4 beam sets and a hand pump. Stops should be ordered separately specifying the pipe diameter , SDR to be squeezed off and the quantity required. Unit can be requested with an air intensifier power unit as an alternative to the hand pump (pneumatic input/hydraulic output)

FEATURES

The basic tool allows four squeeze-off points to be carried out concurrently, quickly and effectively.Centrally mounted hydraulic cylinder compressing two round profile beams against the pipe.Fast on-site assembly to squeeze timeTool-less exchange of end gauges if requiredQuick connecting hydraulic linesSpring return hand pumpSafety stops to prevent creep also permit controlled release

SQT50A supplied with -1 x A frame with integral spring return hydraulic cylinder4 x top and bottom bar beam sets (no stops included)1 x hand pump

SQT50AECON supplied with - 1 x Aframe with integral spring return hydraulic cylinder1 x top and bottom bar beam sets (no stops included)1 x hand pump

Note: For correct site practice, rerounding clamps should be used after squeeze-off is completed.

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SQT50A 180-50mm A frame squeeze tool complete with sufficient equipment for 4 squeeze-offs (stops to be purchased separately) 153kg

SQT50AECON 180-50mm A frame squeeze tool complete with sufficient equipment for 1 squeeze-off (stops to be purchased separately)

75kg

69055 Air intensifier for above squeeze tool range 15kg

SPECIFICATIONS

SAFETY STOPSStops should be ordered separately and bought in pairs. Please specify the pipe diameter, SDR to be squeezed off and the quantity required.

Product Code Pipe Diameter / SDR

Stops for SQT250A / SQT250AECON

35885/180-11 180 SDR11

35885/180-17 180 SDR17

35885/180-17.6 180 SDR17.6

35885/00-11 00 SDR11

35885/00-17 00 SDR17

35885/00-17.6 00 SDR17.6

35885/00-1 00 SDR1

35885/00-6 00 SDR6

35885/13-6 13 SDR6

35885/5-11 5 SDR11

35885/5-17 5 SDR17

35885/5-17.6 5 SDR17.6

35885/5-1 5 SDR1

35885/5-6 5 SDR6

35885/50-11 50 SDR11

35885/50-17 50 SDR17

35885/50-17.6 50 SDR17.6

35885/50-1 50 SDR1

35885/50-6 50 SDR6

35885/68-6 68 SDR6

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Note: For correct site practice, rerounding clamps should be used after squeeze-off is completed.

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This drill is for use in non-pressure applications and allows the operator to creat

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Butt Fusion and Electrofusion Equipment and Tooling

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